Disc brake pad retention system and mounting method

Abstract

An apparatus and method are provided for suppressing undesired brake pad motion during brake application, and for installing and removing brake pads utilizing the inventive arrangements. One embodiment of the invention includes brake pads and a carrier mount having complementary surface features that retain the brake pad when the brake pad is in its installed position and a brake pad biasing structure that biases the brake pad in the radially outward direction to bias contact faces of the mount horn and the brake pad against one another to suppress brake pad kick and vibration and related wear and component fatigue.

What is claimed is: 
     
       1. A brake pad motion suppression system for a disc brake, comprising:
 a brake caliper; 
 a brake pad; 
 a carrier mount having brake pad abutment surfaces configured to receive the brake pad; 
 a brake pad biasing structure, 
 wherein
 a lateral side of the brake pad and a brake pad abutment surface of the carrier mount have complementary surface features configured to retain the brake pad in the disc brake in a radially outward direction, 
 the brake pad biasing structure biases a face of the surface feature of the brake pad in the radially outward direction against a face of the surface feature of the brake pad abutment surface, and 
 the brake pad biasing structure applies a biasing force in the radially outward direction to an upper portion of a backing plate of the brake pad. 
 
 
     
     
       2. The brake pad motion suppression system of  claim 1 , wherein
 the brake pad biasing structure includes at least one spring configured to bias the brake pad in the radially outward direction. 
 
     
     
       3. The brake pad motion suppression system of  claim 2 , wherein
 the brake pad biasing structure includes a spring support configured to support the at least one spring when the spring is applying the radially outward biasing force to the brake pad. 
 
     
     
       4. The brake pad motion suppression system of  claim 3 , wherein
 the brake pad biasing structure includes a spring reaction bar supported on the brake caliper and supporting the at least one spring. 
 
     
     
       5. The brake pad motion suppression system of  claim 4 , wherein
 the surface feature of the brake pad abutment surface is wedge-shaped. 
 
     
     
       6. The brake pad motion suppression system of  claim 4 , wherein
 a radially outer surface of the upper portion of the brake pad backing plate includes at least one spring receiving feature configured to cooperate with the at least one spring to bias the brake pad in the radially outward direction. 
 
     
     
       7. The brake pad motion suppression system of  claim 6 , wherein
 the at least one brake pad backing plate spring receiving feature is configured to receive an S-shaped tip of the at least one spring. 
 
     
     
       8. The brake pad motion suppression system of  claim 6 , wherein
 the at least one brake pad backing plate spring receiving feature is configured to receive a tip of the at least one spring having a spring retaining feature configured to cooperate with a corresponding spring retaining feature of the at least one brake pad backing plate spring receiving feature. 
 
     
     
       9. The brake pad motion suppression system of  claim 8 , wherein
 the spring retaining feature of the at least one brake pad backing plate spring receiving feature is a hook-shaped protrusion and the spring retaining feature of the tip of the at least one spring is a depression configured to cooperate with the hook-shaped protrusion to inhibit movement of the tip away from the at least one brake pad backing plate spring receiving feature. 
 
     
     
       10. The brake pad motion suppression system of  claim 6 , further comprising:
 at least one spring insert configured to be located between the spring reaction bar and the at least one spring. 
 
     
     
       11. The brake pad motion suppression system of  claim 10 , wherein
 at least one of the at least one spring insert and the spring reaction bar is configured increase the radially outward biasing force applied by the at least one spring to the brake.